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It sounds to me like a part is missing in the clutch assembly. Bear in mind that the first plate installed in the clutch assembly is a cork friction plate, then metal, cork, metal, ect.. You should end up with a cork friction plate. There should be 6 metal plates and 7 cork friction plates. The diagram below is a tri-z 250. Please rate my answer. Thanks!
In order to remove the clutch from your bike, you must have a special tool. You'll need H-D #34761 in order to remove the snap ring holding the clutch together.
Disconnect the battery, drain the primary, and remove the primary cover. Once you have the primary cover off, you can remove the nut from the compensator sprocket at the engine end of the primary chain.
Install the H-D 34761 or equivalent tool and compress the clutch spring. Remove the snap ring and then back off on the tool to release the pressure on the clutch spring. Once the pressure has been removed, remove the adjusting screw assembly, the outer clutch spring seats, the clutch spring, the inner clutch spring seat, and the pressure plate.
Then you can disassemble the rest of the clutch. Remove the remove the four friction plates and three drive plates. Then you can remove the spring plate and the remaining plates after that. Remove the snap ring that holds the clutch assembly onto the transmission clutch gear and remove the inner and outer clutch shells, the primary chain, and the engine sprocket as a group.
For this job, I would recommend that you purchase a service manual. It's has pictures that show you what you're dealing with and in this case, a picture is truly worth a thousand words.
The clutch cable hooks to the screw assembly. The assembly is bolted to the case. When the clutch lever is pulled in, the center part of the assembly, ( a giant screw mechanism ), pushes on the clutch rod which then pushes on the outer clutch pressure plate to separate the clutch plates. The clutch springs supply the pressure to push the clutch lever outward thus engaging the clutch to move forward. I hope this answers your question. Please rate my answer. Thanks.
Remove the right case cover. Remove the five bolts and springs on the pressure plate then remove the plate. Remove all the clutch plates then insert the new plates in sequence matching how they came out, i.e., a fiber friction plate goes in first, the a metal pressure plate, then friction then pressure etc. You should end with a friction plate on the outside. Reuse the old metal pressure plates unless they are warped. Generally speaking, the metal plates don't wear out. The friction plates do wear out.
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Go to the site
below where you can see a parts diagram for your specific bike. You will select
the actual brand, year, model, etc., once you go to the site. Part numbers and
prices are also shown. You can order parts from this site. In the event no
price is shown on a particular part and/or the notation "Not
Available" is in the description, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx Please rate my answer. Thanks!
It sounds like the clutch must be incorrectly assembled. No offense meant, is is easy to miss one little thing. Go to the site below and look at the clutch diagram. Note that the assembly begins and ends with a friction plate and that a metal pressure plate goes between each friction plate. You should have 7 metal pressure plates and 8 friction plates.
The clutch outer basket seldom goes bad unless hit with a hammer or a tree. Why did it need to be replaced? Did you compare the new OEM hub to the old one? They may have given you the wrong basket. The tighter the cable the less likely the clutch will engage. You should have 1/4" end play at the handlebar lever. By the way, exactly what oil did you put in the gearbox after replacing the clutch? Okay, this is a good start. Post a comment if you need to get back to me.
Remove drive shaft,remove crossmember under transmission.Remove transmission and diconnect linkage.Remove bell housing,and clutch berring assembely.Remove bolts on pressure plate.Once this is done.Remove fly wheel for machineing.you will need a pilot shaft to alighn clutch assemblely.Possible one will come with new clutch and pressure plate.Reverse assemblely in same order remember to torque all your bolts with torque wrench.Take your time.
Just put it back the same way you took it off. If you buy the right clutch kit (Sachs I think) it should come with a disc alignment tool. Remember to tighten the pressure plate bolts evenly all the way around the plate. And don't forget the pilot bushing or bearing.
There is a retaining clip that holds the plates in the basket. The assembly will need to be depressed in order to get the retainer in place. You can get a diagram, or at least view the diagram for the assembly at the parts counter of your local HD dealer. The local dealer here has stopped printing out the diagrams for me, but will still let me view them. Generally that's all you need anyway, just to get the idea.
Removal (3000GT AWD) 1. Remove air cleaner cover, air hoses and vacuum pipe. Remove air cleaner, intake hose, battery, battery tray and washer tank. 2. Disconnect transaxle control cables and speedometer cable. Raise and support vehicle. 3. Remove both inner fender splash shields. Remove clutch tube bracket and disconnect clutch release cylinder (including clutch damper assembly on FWD models) and wire aside. Support transaxle assembly with jack and disconnect upper transaxle mount. Remove mount, bracket, plug and stoppers. 4. Remove transaxle assembly upper coupling bolts. Disconnect tie rod ends and lower arm ball joints. Remove right support member, starter cover (if equipped) and starter. 5. Remove left side bearing bracket mounting bolts and pry left axle shaft from transaxle. Wire left axle shaft and inner shaft assembly aside. Pry right axle shaft from transaxle and wire aside. 6. Remove front bank side and rear bank side transaxle stays. Support transaxle assembly with a transmission jack. Remove transaxle assembly lower coupling bolts and lower transaxle from vehicle. 7. Insert a clutch alining tool to prevent pressure plate and clutch disc from falling. Loosen pressure plate bolts gradually in a crisscross pattern to avoid warping pressure plate flange. Remove pressure plate and clutch disc.